Heat exchange mechanism for removing contaminants from a hydrocarbon vapor stream

ABSTRACT

A system for melting contaminant-laden solids that have been separated from a hydrocarbon-containing vapor stream in a hydrocarbon distillation tower, comprising at least one plate positioned where the solids form within the hydrocarbon distillation tower, hollow tubing forming an integral part of each of the at least one plate, and a heating medium disposed to flow through the hollow tubing at a higher temperature than a temperature of the solids to at least partially melt the solids.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the priority benefit of U.S. Patent ApplicationSer. No. 62/080,450 filed Nov. 17, 2014, the entirety of which isincorporated by reference herein.

BACKGROUND

Fields of Disclosure

The disclosure relates generally to the field of fluid separation. Morespecifically, the disclosure relates to the cryogenic separation ofcontaminants, such as acid gas, from a hydrocarbon.

Description of Related Art

This section is intended to introduce various aspects of the art, whichmay be associated with the present disclosure. This discussion isintended to provide a framework to facilitate a better understanding ofparticular aspects of the present disclosure. Accordingly, it should beunderstood that this section should be read in this light, and notnecessarily as admissions of prior art.

The production of natural gas hydrocarbons, such as methane and ethane,from a reservoir oftentimes carries with it the incidental production ofnon-hydrocarbon gases. Such gases include contaminants, such as at leastone of carbon dioxide (“CO₂”), hydrogen sulfide (“H₂S”), carbonylsulfide, carbon disulfide and various mercaptans. When a feed streambeing produced from a reservoir includes these contaminants mixed withhydrocarbons, the stream is oftentimes referred to as “sour gas.”

Many natural gas reservoirs have relatively low percentages ofhydrocarbons and relatively high percentages of contaminants.Contaminants may act as a diluent and lower the heat content ofhydrocarbons. Additionally, in the presence of water some contaminantscan become quite corrosive.

It is desirable to remove contaminants from a stream containinghydrocarbons to produce sweet and concentrated hydrocarbons.Specifications for pipeline quality natural gas typically call for amaximum of 2-4% CO₂ and ¼ grain H₂S per 100 scf (4 ppmv) or 5 mg/Nm³H₂S. Specifications for lower temperature processes such as natural gasliquefaction plants or nitrogen rejection units typically require lessthan 50 ppm CO₂.

The separation of contaminants from hydrocarbons is difficult andconsequently significant work has been applied to the development ofhydrocarbon/contaminant separation methods. These methods can be placedinto three general classes: absorption by solvents (physical, chemicaland hybrids), adsorption by solids, and distillation.

Separation by distillation of some mixtures can be relatively simpleand, as such, is widely used in the natural gas industry. However,distillation of mixtures of natural gas hydrocarbons, primarily methane,and one of the most common contaminants in natural gas, carbon dioxide,can present significant difficulties. Conventional distillationprinciples and conventional distillation equipment are predicated on thepresence of only vapor and liquid phases throughout the distillationtower. The separation of CO₂ from methane by distillation involvestemperature and pressure conditions that result in solidification of CO₂if pipeline or better quality hydrocarbon product is desired. Therequired temperatures are cold temperatures typically referred to ascryogenic temperatures.

Certain cryogenic distillations can overcome the above mentioneddifficulties. These cryogenic distillations provide the appropriatemechanism to handle the formation and subsequent melting of solidsduring the separation of solid-forming contaminants from hydrocarbons.The formation of solid contaminants in equilibrium with vapor-liquidmixtures of hydrocarbons and contaminants at particular conditions oftemperature and pressure takes place in a controlled freeze zonesection.

A frozen solids accumulation and melt (A&M) section of the controlledfreeze zone region of a distillation tower may be designed to: (a) passvapor from the section below the A&M section to the section above; (b)accumulate the solid contaminants; (c) melt the accumulated solidcontaminants; and (d) remove the melted contaminants. FIGS. 1 and 2 showa typical design for an A&M section 1, where FIG. 1 illustrates anelevational view of the A&M and FIG. 2 illustrates a cross-section viewof the A&M. The A&M section 1 is disposed within the walls 2 of acontrolled freeze zone section 3. The A&M section 1 is comprised of aplurality of vapor risers 4 and one or more coils of tubing 5 or heatingelements arranged around the vapor risers 4. Ideally, frozenparticulates fall into the interstitial space between the coils oftubing 5 and accumulate over time. At a set time, a heating medium flowsthrough the coils of tubing 5 to melt the accumulated frozen mass. Themelted mass then exits A&M section 1.

Within the confines of the design depicted in FIGS. 1 and 2, dependingon the operating conditions and physical characteristics of the frozenparticles, such particles may not fall into and accumulate in theinterstitial spacing between the tube coils. Rough surfaces and surfaceimperfections serve as a nucleation points for particle deposition andpromote agglomeration with additional particles. Frozen particles mayaccumulate on, but not limited to: (a) the walls of the tubes in thecoils of tubing 5; (b) the walls of the vapor risers 4; (c) the coversof the vapor risers 4; (d) surface imperfections on the wall 2 of theA&M section 1; and (e) other internal structures in the controlledfreeze zone section 3 immediately above the A&M section 1. If not incontact with or exposed to the coils of tubing, the accumulated frozenmass may be effectively removed from the melting process, reducing itseffectiveness.

Therefore, a need exists for improved technology to effectively melt theaccumulated frozen mass in a controlled freeze zone unit. There is alsoa need for improved technology in a controlled freeze zone unit thatreduces uneven collection and agglomeration of frozen particulateswithin the desired accumulation region. Further, there is a need forimproved technology in a controlled freeze zone unit that reduces frozenparticulate accumulation outside of the designated region.

SUMMARY

The present disclosure provides a means to selectively meltcontaminant-laden solids or semi-solids in a hydrocarbon distillationprocess.

In one aspect, the disclosure includes a system for meltingcontaminant-laden solids that have been separated from ahydrocarbon-containing vapor stream in a hydrocarbon distillation tower,comprising at least one plate positioned where the solids form withinthe hydrocarbon distillation tower, hollow tubing forming an integralpart of each of the at least one plate, and a heating medium disposed toselectively flow through the hollow tubing at a higher temperature thana temperature of the solids to at least partially melt the solids.

In another aspect, a method is disclosed for separating a feed stream ina distillation tower comprising maintaining a controlled freeze zonesection in the distillation tower that receives a freezing zone liquidstream to form a solid and a hydrocarbon-enriched vapor stream in thecontrolled freeze zone section, melting the solid using a heat exchangemechanism, wherein melting includes flowing a heating medium through ahollow tubing integrally disposed in a plate positioned where the solidsform within the controlled freeze zone section, wherein the heatingmedium is at a higher temperature than the temperature of the solid,collecting the solid that has been at least partially melted by the heatexchange mechanism, and separating the at least partially melted solidfrom the hydrocarbon-enriched vapor stream.

In still another aspect, the disclosure includes a method for producinghydrocarbons comprising maintaining a controlled freeze zone section inthe distillation tower that receives a freezing zone liquid stream toform a solid and a hydrocarbon-enriched vapor stream in the controlledfreeze zone section, melting at least a portion of the solid using aheat exchange mechanism, wherein melting comprises heating a heatingmedium to a higher temperature than the temperature of the solid,flowing the heating medium through a hollow tubing integrally disposedin at least one plate positioned where the solid forms within thecontrolled freeze zone section, collecting the solid that has been atleast partially melted by the heat exchange mechanism, disposing of theat least partially melted solid, and passing the hydrocarbon-enrichedvapor stream from the distillation tower.

The foregoing has broadly outlined the features of the presentdisclosure so that the detailed description that follows may be betterunderstood. Additional features will also be described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the disclosure willbecome apparent from the following description, appending claims and theaccompanying drawings, which are briefly described below.

FIG. 1 is a top elevational view of an accumulation and melt (A&M)section in a distillation tower.

FIG. 2 is a cross-section of the A&M section in FIG. 1.

FIG. 3 is a schematic diagram of a distillation tower with sectionswithin a single vessel.

FIG. 4 is a schematic diagram of a tower with sections within multiplevessels.

FIG. 5 is a schematic diagram of a tower with sections within a singlevessel.

FIG. 6 is a schematic diagram of a tower with sections within multiplevessels.

FIG. 7 is a detailed schematic diagram of a portion of any of the towersof FIGS. 3-6.

FIG. 8 is a perspective view of a heat exchange mechanism.

FIG. 9 is a cross-section of the heat exchange mechanism of FIG. 8 takenalong line 9-9.

FIG. 10 is a perspective view of another heat exchange mechanism.

FIG. 11 is a perspective view of another heat exchange mechanism.

FIG. 12 is a perspective view of another heat exchange mechanism.

FIGS. 13A & 13B are perspective views of risers used with the heatexchange mechanisms disclosed herein.

FIG. 14 is a cutaway view of a riser in FIG. 13 taken along line 14-14.

FIG. 15 is a side view of a riser and cap according to the disclosure.

FIG. 16 is a sectional view taken along line 16-16 in FIG. 15.

FIG. 17 is a schematic diagram of a heat exchanger sub-system.

FIG. 18 is a block diagram of a method according to the disclosure.

FIG. 19 is a block diagram of another method according to thedisclosure.

It should be noted that the figures are merely examples and nolimitations on the scope of the present disclosure are intended thereby.Further, the figures are generally not drawn to scale, but are draftedfor purposes of convenience and clarity in illustrating various aspectsof the disclosure.

DETAILED DESCRIPTION

For the purpose of promoting an understanding of the principles of thedisclosure, reference will now be made to the features illustrated inthe drawings and specific language will be used to describe the same. Itwill nevertheless be understood that no limitation of the scope of thedisclosure is thereby intended. Any alterations and furthermodifications, and any further applications of the principles of thedisclosure as described herein are contemplated as would normally occurto one skilled in the art to which the disclosure relates. It will beapparent to those skilled in the relevant art that some features thatare not relevant to the present disclosure may not be shown in thedrawings for the sake of clarity.

As referenced in this application, the terms “stream,” “gas stream,”“vapor stream,” and “liquid stream” refer to different stages of a feedstream as the feed stream is processed in a distillation tower thatseparates methane, the primary hydrocarbon in natural gas, fromcontaminants. Although the phrases “gas stream,” “vapor stream,” and“liquid stream,” refer to situations where a gas, vapor, and liquid ismainly present in the stream, respectively, there may be other phasesalso present within the stream. For example, a gas may also be presentin a “liquid stream.” In some instances, the terms “gas stream” and“vapor stream” may be used interchangeably.

The disclosure relates to a system and method for removing contaminantsfrom a hydrocarbon stream. FIGS. 1-19 of the disclosure display variousaspects of the system and method.

The system and method may separate a feed stream having methane andcontaminants. The system may comprise a distillation tower 104, 204(FIGS. 3-6). The distillation tower 104, 204 may separate thecontaminants from the methane.

The distillation tower 104, 204 may be separated into three functionalsections: a lower section 106, a middle controlled freeze zone section108, and an upper section 110. The distillation tower 104, 204 mayincorporate three functional sections when the upper section 110 isneeded and/or desired.

The distillation tower 104, 204 may incorporate only two functionalsections when the upper section 110 is not needed and/or desired. Forexamples, in embodiments where the distillation tower does not includean upper section 110, a portion of vapor leaving the middle controlledfreeze zone section 108 may be condensed in a condenser 122 and returnedas a liquid stream via a spray assembly 129. Moreover, in suchembodiments FIG. 3 may be modified such that lines 18 and 20 may beeliminated, elements 124 and 126 may be one and the same, and elements150 and 128 may be one and the same. The stream in line 14, now takingthe vapors leaving the middle controlled freeze section 108, directsthese vapors to the condenser 122.

Returning to FIGS. 3-6, the lower section 106 may be referred to as astripper section. The middle controlled freeze zone section 108 may bereferred to as a controlled freeze zone section. The upper section 110may be referred to as a rectifier section.

The sections of the distillation tower 104 may be housed within a singlevessel (FIGS. 3 and 5). For example, the lower section 106, the middlecontrolled freeze zone section 108, and the upper section 110 may behoused within a single vessel 164.

In some embodiments, the sections of the distillation tower 204 may behoused within a plurality of vessels to form a split-tower configuration(FIGS. 4 and 6). Each of the vessels may be separate from the othervessels. Piping and/or another suitable mechanism may connect one vesselto another vessel. In this instance, the lower section 106, middlecontrolled freeze zone section 108, and upper section 110 may be housedwithin two or more vessels. For example, as shown in FIGS. 4 and 6, theupper section 110 may be housed within a single vessel 254 and the lowerand middle controlled freeze zone sections 106, 108 may be housed withina single vessel 264. When this is the case, a liquid stream exiting theupper section 110 may exit through a liquid outlet bottom 260. Theliquid outlet bottom 260 is at the bottom of the upper section 110.Although not shown, each of the sections may be housed within its ownseparate vessel, or one or more section may be housed within separatevessels, or the upper and middle controlled freeze zone sections may behoused within a single vessel and the lower section may be housed withina single vessel, etc. When sections of the distillation tower are housedwithin vessels, the vessels may be disposed in many possibleorientations, such as side-by-side along a horizontal line and/or aboveeach other along a vertical line.

The split-tower configuration may be beneficial in situations where theheight of the distillation tower, motion considerations, and/ortransportation issues, such as for remote locations, need to beconsidered. This split-tower configuration allows for the independentoperation of one or more sections. For example, when the upper sectionis housed within a single vessel and the lower and middle controlledfreeze zone sections are housed within another single vessel,independent generation of reflux liquids using a substantiallycontaminant-free, largely hydrocarbon stream from a packed gas pipelineor an adjacent hydrocarbon line, may occur in the upper section. Thereflux may be used to cool the upper section, establish an appropriatetemperature profile in the upper section, and/or build up liquidinventory at the bottom of the upper section to serve as an initialsource of spray liquids for the middle controlled freeze zone section.Moreover, the middle controlled freeze zone and lower sections may beindependently prepared by (a) chilling the feed stream, (b) feeding thechilled feed stream to the optimal location in the lower section or inthe middle controlled freeze zone section, (c) generating liquids forthe lower and the middle controlled freeze zone sections, and (d)disposing of the vapors off the middle controlled freeze zone section ifthe vapors are off specification with too high a contaminant content.Also, liquid from the upper section may be intermittently orcontinuously sprayed, which builds up liquid level in the bottom of themiddle controlled freeze zone section and reduces the contaminantcontent in the middle controlled freeze zone section to a near steadystate level. In this manner the two vessels may be connected to send thevapor stream from the middle controlled freeze zone section to the uppersection, continuously spraying liquid from the bottom of the uppersection into the middle controlled freeze zone section and stabilizingoperations into steady state conditions. The split tower configurationmay use a sump of the upper section as a liquid receiver for the pump128, thereby obviating the need for a liquid receiver 126 in FIGS. 3 and5.

The system may also include a heat exchanger 100 (FIGS. 3-6). The feedstream 10 may enter the heat exchanger 100 before entering thedistillation tower 104, 204. The feed stream 10 may be cooled within theheat exchanger 100. The heat exchanger 100 helps drop the temperature ofthe feed stream 10 to a level suitable for introduction into thedistillation tower 104, 204.

The system may include an expander device 102 (FIGS. 3-6). The feedstream 10 may enter the expander device 102 before entering thedistillation tower 104, 204. The feed stream 10 may be expanded in theexpander device 102 after exiting the heat exchanger 100. The expanderdevice 102 helps drop the temperature of the feed stream 10 to a levelsuitable for introduction into the distillation tower 104, 204. Theexpander device 102 may be any suitable device, such as a valve. If theexpander device 102 is a valve, the valve may be any suitable valve thataids in cooling the feed stream 10 before it enters the distillationtower 104, 204. For example, the valve 102 may comprise a Joule-Thompson(J-T) valve.

The system may include a feed separator 103 (FIGS. 5-6). The feed streamenters the feed separator before entering the distillation tower 104,204. The feed separator separates a feed stream having a mixed liquidand vapor stream into a liquid stream and a vapor stream. Lines 12extend from the feed separator to the distillation tower 104, 204. Oneof the lines 12 may receive the vapor stream from the feed separator.Another one of the lines 12 may receive the liquid stream from the feedseparator. Each of the lines 12 may extend to the same and/or differentsections (i.e. middle controlled freeze zone, and lower sections) of thedistillation tower 104, 204. The expander device 102 may or may not bedownstream of the feed separator 103. The expander device 102 maycomprise a plurality of expander devices 102 such that each line 12 hasan expander device 102.

The system may include a dehydration unit 261 (FIGS. 3-6). The feedstream 10 may enter the dehydration unit 261 before entering thedistillation tower 104, 204. The feed stream 10 enters the dehydrationunit 261 before entering the heat exchanger 100 and/or the expanderdevice 102. The dehydration unit 261 removes water from the feed stream10 to prevent water from later presenting a problem in the heatexchanger 100, expander device 102, feed separator 103, or distillationtower 104, 204. The water can present a problem by forming a separatewater phase (i.e., ice and/or hydrate) that plugs lines, equipment ornegatively affects the distillation process. The dehydration unit 261dehydrates the feed stream to a dew point sufficiently low to ensure aseparate water phase will not form at any point downstream during therest of the process. The dehydration unit may be any suitabledehydration mechanism, such as a molecular sieve or a glycol dehydrationunit.

The system may include a filtering unit (not shown). The feed stream 10may enter the filtering unit before entering the distillation tower 104,204. The filtering unit may remove undesirable contaminants from thefeed stream before the feed stream enters the distillation tower 104,204. Depending on what contaminants are to be removed, the filteringunit may be before or after the dehydration unit 261 and/or before orafter the heat exchanger 100.

The system may include a line 12 (FIGS. 3-6). The line may be referredto as an inlet channel 12. The feed stream 10 may be introduced into thedistillation tower 104, 204 through the line 12. The line 12 may extendto the lower section 106 or the middle controlled freeze zone section108 of the distillation tower 104, 204. For example, the line 12 mayextend to the lower section 106 such that the feed stream 10 may enterthe lower section 106 of the distillation tower 104, 204 (FIGS. 3-6).The line 12 may directly or indirectly extend to the lower section 106or the middle controlled freeze zone section 108. The line 12 may extendto an outer surface of the distillation tower 104, 204 before enteringthe distillation tower 104, 204.

If the system includes the feed separator 103 (FIGS. 5-6), the line 12may comprise a plurality of lines 12. Each line extends from the feedseparator to a specific portion of the distillation tower 104, 204.

The lower section 106 is constructed and arranged to separate the feedstream 10 into an enriched contaminant bottom liquid stream (i.e.,liquid stream) and a freezing zone vapor stream (i.e., vapor stream).The lower section 106 separates the feed stream at a temperature andpressure at which no solids form. The liquid stream may comprise agreater quantity of contaminants than of methane. The vapor stream maycomprise a greater quantity of methane than of contaminants. In anycase, the vapor stream is lighter than the liquid stream. As a result,the vapor stream rises from the lower section 106 and the liquid streamfalls to the bottom of the lower section 106.

The lower section 106 may include and/or connect to equipment thatseparates the feed stream. The equipment may comprise any suitableequipment for separating methane from contaminants, such as one or morepacked sections 181, or one or more distillation trays withperforations, downcomers, and weirs (FIGS. 3-6).

The equipment may include components that apply heat to the stream toform the vapor stream and the liquid stream. For example, the equipmentmay comprise a first reboiler 112 that applies heat to the stream. Thefirst reboiler 112 may be located outside of the distillation tower 104,204. The equipment may also comprise a second reboiler 172 that appliesheat to the stream. The second reboiler 172 may be located outside ofthe distillation tower 104, 204. Line 117 may lead from the distillationtower to the second reboiler 172. Line 17 may lead from the secondreboiler 172 to the distillation tower. Additional reboilers, set upsimilarly to the second reboiler described above, may also be used.

The first reboiler 112 applies heat to the liquid stream that exits thelower section 106 through a liquid outlet 160 of the lower section 106.The liquid stream travels from the liquid outlet 160 through line 28 toreach the first reboiler 112 (FIGS. 3-6). The amount of heat applied tothe liquid stream by the first reboiler 112 can be increased to separatemore methane from contaminants. The more heat applied by the reboiler112 to the stream, the more methane can be separated from the liquidcontaminants, though more contaminants will also be vaporized.

The first reboiler 112 may also apply heat to the stream within thedistillation tower 104, 204. Specifically, the heat applied by the firstreboiler 112 warms up the lower section 106. This heat travels up thelower section 106 and supplies heat to warm solids entering a melt trayassembly 139 (FIGS. 3-6) of the middle controlled freeze zone section108 so that the solids form a liquid and/or slurry mix.

The second reboiler 172 applies heat to the stream within the lowersection 106. This heat is applied closer to the middle controlled freezezone section 108 than the heat applied by the first reboiler 112. As aresult, the heat applied by the second reboiler 172 reaches the middlecontrolled freeze zone section 108 faster than the heat applied by thefirst reboiler 112. The second reboiler 172 also helps with energyintegration.

The equipment may include one or more chimney assemblies 135 (FIGS.3-6). While falling to the bottom of the lower section 106, the liquidstream may encounter one or more of the chimney assemblies 135.

Each chimney assembly 135 includes a chimney tray 131 that collects theliquid stream within the lower section 106. The liquid stream thatcollects on the chimney tray 131 may be fed to the second reboiler 172.After the liquid stream is heated in the second reboiler 172, the streammay return to the middle controlled freeze zone section 108 to supplyheat to the middle controlled freeze zone section 108 and/or the melttray assembly 139. Unvaporized portions of the stream exiting the secondreboiler 172 may be fed back to the distillation tower 104, 204 belowthe chimney tray 131. Vapor stream exiting the second reboiler 172 maybe routed under or above the chimney tray 131 when the vapor streamenters the distillation tower 104, 204.

The chimney tray 131 may include one or more chimneys 137. The chimney137 serves as a channel that the vapor stream in the lower section 106traverses. The vapor stream travels through an opening in the chimneytray 131 at the bottom of the chimney 137 to the top of the chimney 137.The opening is closer to the bottom of the lower section 106 than it isto the bottom of the middle controlled freeze zone section 108. The topis closer to the bottom of the middle controlled freeze zone section 108than it is to the bottom of the lower section 106.

Each chimney 137 has attached to it a chimney cap 133. The chimney cap133 covers a chimney top opening 138 of the chimney 137. The chimney cap133 prevents liquid from entering the chimney 137 directly from thesection above the chimney 137. The vapor stream exits the chimneyassembly 135 via the chimney top opening 138.

After falling to the bottom of the lower section 106, the liquid streamexits the distillation tower 104, 204 through the liquid outlet 160. Theliquid outlet 160 is within the lower section 106 (FIGS. 3-6). Theliquid outlet 160 may be located at the bottom of the lower section 106.

After exiting through the liquid outlet 160, the feed stream may travelvia line 28 to the first reboiler 112. The feed stream may be heated bythe first reboiler 112 and vapor may then re-enter the lower section 106through line 30. Unvaporized liquid may continue out of the distillationprocess via line 24.

The system may include an expander device 114 (FIGS. 3-6). Afterentering line 24, the heated liquid stream may be expanded in theexpander device 114. The expander device 114 may be any suitable device,such as a valve. Any suitable valve may be used, such as a J-T valve.

The system may include a heat exchanger 116 (FIGS. 3-6). The liquidstream heated by the first reboiler 112 may be cooled or heated by theheat exchanger 116. The heat exchanger 116 may be a direct heatexchanger or an indirect heat exchanger. The heat exchanger 116 maycomprise any suitable heat exchanger and may output a discharge stream26.

The vapor stream in the lower section 106 rises from the lower section106 to the middle controlled freeze zone section 108. The middlecontrolled freeze zone section 108 is maintained to receive a freezingzone liquid stream to form the solid and the vapor stream (i.e.,hydrocarbon-enriched vapor stream) in the middle controlled freeze zonesection 108. The middle controlled freeze zone section 108 isconstructed and arranged to separate the feed stream 10 introduced intothe middle controlled freeze zone section into a solid and a vaporstream. The solid and the vapor stream are formed in the middlecontrolled freeze zone section 108 when the freezing zone liquid streamis injected into the middle controlled freeze zone section 108 at atemperature and pressure at which the solid and vapor stream form. Thesolid may be comprised more of contaminants than of methane. The vaporstream may comprise more methane than contaminants.

The middle controlled freeze zone section 108 includes a lower section40 and an upper section 39 (FIG. 7). The lower section 40 is below theupper section 39. The lower section 40 directly abuts the upper section39. The lower section 40 is primarily but may not exclusively be aheating section of the middle controlled freeze zone section 108. Theupper section 39 is primarily but may not exclusively be a coolingsection of the middle controlled freeze zone section 108. Thetemperature and pressure of the upper section 39 are chosen so that thesolid can form in the middle controlled freeze zone section 108.

The middle controlled freeze zone section 108 may comprise a melt trayassembly 139 that is maintained in the middle controlled freeze zonesection 108 (FIGS. 3-7). The melt tray assembly 139 is within the lowersection 40 of the middle controlled freeze zone section 108. The melttray assembly 139 is not within the upper section 39 of the middlecontrolled freeze zone section 108.

The melt tray assembly 139 is constructed and arranged to melt a solidformed in the middle controlled freeze zone section 108. When the warmvapor stream rises from the lower section 106 to the middle controlledfreeze zone section 108, the vapor stream immediately encounters themelt tray assembly 139 and supplies heat to melt the solid. The melttray assembly 139 may comprise at least one of a melt tray 118, a bubblecap 132, a liquid 130, and a heat exchange mechanism(s) 134.

The melt tray 118 may collect a liquid and/or slurry mix. The melt tray118 divides at least a portion of the middle controlled freeze zonesection 108 from the lower section 106. The melt tray 118 is at thebottom 45 of the middle controlled freeze zone section 108.

One or more bubble caps 132 may act as a channel for the vapor streamrising from the lower section 106 to the middle controlled freeze zonesection 108. The bubble cap 132 may provide a path for the vapor streamthat forces the vapor stream up the riser 140 and then down and aroundthe riser 140 to the melt tray 118. The riser 140 is covered by a cap141. The cap 141 forms a passage around the riser 140 through which thevapor stream flows. The vapor stream's traversal through the bubble cap132 allows the vapor stream to transfer heat to the liquid 130 withinthe melt tray assembly 139.

One or more heat exchange mechanisms 134 may further heat up the liquid130 to facilitate melting of the solids into a liquid and/or slurry mix.The heat exchange mechanism(s) 134 may be located anywhere within themelt tray assembly 139. For example, as shown in FIGS. 3-7, a heatexchange mechanism 134 may be located around the bubble caps 132. Theheat mechanism 134 may be any suitable mechanism, such as a heat coil.The heat source of the heat exchange mechanism 134 may be any suitableheat source.

In one aspect of the disclosure shown in FIG. 8, the heat exchangemechanism 134 is a plurality of plates 300 having hollow tubing formingan integral part of the plates, e.g., in a parallel, coiled, helical, orserpentine configuration (FIG. 9). The tubing 302 is attached to aninlet manifold 304 that directs a heating medium into the tubing 302.The heating medium exits the tubing through an outlet manifold 306. Theheating medium may be any fluid, either liquid or vapor, that is warmerthan the fluid or solid to be heated. As a liquid, the heating mediummay be water, a hydrocarbon, or a mixture thereof. The inner surface 303of tubing 302 may be smooth, or alternatively may comprise an irregulartexture or shape to enhance fluid flow and/or heat exchangecharacteristics of the tubing, e.g., ridges, bumps, channels, slots,grooves, holes, other equivalent structures, or various combinationsthereof.

In the aspect shown in FIG. 8, the substantially concentric plates 300are curved to fit within the middle controlled freeze zone section 108.The curvature of plates 300 can be optimized to meet requiredaccumulation cross-sectional area and volume, as well as to accommodatethe risers 140 (FIGS. 3-7). For example, FIG. 10 shows a heat exchangemechanism 134 where the concentric plates 300 are substantially fullycircular in shape, and are designed to fit around a riser (FIGS. 3-7).Although the plates in FIGS. 8 and 10 are shown as being substantiallyparallel to each other, it is possible to vary the angle of the plateswith respect to each other and the vessel walls to meet the requiredaccumulation cross-sectional area and volume. Alternatively, the heatexchange mechanism may be modified to include a single plate that isformed in a spiral shape.

Another aspect of the disclosure is shown in FIG. 11, in which aplurality of individual, interconnected coil-in-plate heat exchangers234 are disposed within the middle controlled freeze zone section 108.As with the heat exchangers shown in FIGS. 8 and 10, heat exchangers 234include a plurality of plates 236 and tubing 258 integral with theplates and arranged in a substantially parallel, coiled, or serpentineconfiguration, as shown in FIG. 9. The heat exchangers 234 may besmaller or larger in size than the heat exchangers shown in FIGS. 8 and10. The heat exchangers 234 may be designed to operate all at once or inany combination, with the heating medium directed into a specifiedcombination of the heat exchangers 234 to direct melting of theaccumulated solid material collected between the plates thereof. As withthe aspects shown in FIGS. 8 and 10, the angle of the plates may bevaried with respect to each other and the vessel walls to meet therequired accumulation cross-sectional area and volume.

Another aspect of the disclosure is shown in FIG. 12, in which a heatexchanger 334 includes a conical or frusto-conical plate 336. As withthe heat exchangers shown in FIGS. 8 and 10, plate 336 has tubing 338disposed integrally therewith and arranged in a substantially parallel,coiled, or serpentine configuration, as shown in FIG. 9. The conical orfrusto-conical shape of plate 336 allows for melted accumulation to flowdownward across the coils to the melt tray 118 (FIG. 1). While FIG. 12depicts tubing 338 disposed latitudinally on or in plate 336, the tubing338 may alternatively be disposed helically on or in plate 336 allowingfor the melted accumulation to flow not only downward across the tubing,but also downward along the length of the tubing in a generally spiralor helical direction. The conical or frusto-conical overall shape ofheat exchanger 334 provides a minimal cross-section for accumulation ofsolid material at its apex 340. In contrast, the remainder of heatexchanger 334 provides a substantial cross-sectional surface area forsolids accumulation that is free of other internal tower structures onwhich solids would prematurely stick, accumulate, and form large clumpsthat would interfere with the desired operation of the middle controlledfreeze zone section 108.

If plate 336 is frusto-conical, a single riser may be disposed throughthe opening at the apex 340. Upward flowing vapor may be funneled on theside of the plates opposite of that accumulating the solids into thevapor riser. By only using one vapor riser with heat exchanger 334, thesurface area available for premature solids accumulation away from plate336 is reduced. Optionally, or additionally, if multiple risers aredesired to be used, one or more heat exchangers 334 may be deployedaround each riser.

Regarding the aspects of the disclosure shown in FIGS. 8, 10, and 11,passages or openings such as slots or holes 350 (FIG. 9) may beincorporated in or through the plates 300 (FIG. 9), 236 (FIG. 11) toallow the equilibration of the liquid within the volume occupied by theheat exchanger(s) 134 (FIGS. 8 and 10) and 234 (FIG. 11) to optimizeheat transfer and promote even melting of the collected frozen solids.

According to the disclosed aspects, the risers 140 may be arranged toprovide improved coverage of the vapor within the volume above themiddle controlled freeze zone section 108. A plurality of risers providean additional means to effectively introduce heat to the part of thetower above the middle controlled freeze zone section 108 by passingvapor warmer than the frozen particulates captured in the middlecontrolled freeze zone section. Increasing the cross-sectional area andvolume influenced by the upflowing vapor exiting the risers is expectedto decrease the tendency of frozen particulates from sticking to andagglomerating on surfaces in this portion of the tower by introducing asweeping effect in this region. Disrupting the formation of frozenparticulate structures in this section allows for their formation, asdesigned, in the middle controlled freeze zone section between theplates of the heat exchange mechanism 134, 234, 334.

Various methods may be used to vary the flow patterns of vapor exitingthe riser or risers 140. For example, and as previously discussed, aplurality of risers may be employed. For example, adjacent risers 140may have varying heights with respect to each other. Optionally oradditionally, as shown in FIG. 13A flow pattern inducers such as louvers352 or as shown in FIG. 13B directional slots 354 may be disposed on orin the risers. Optionally or additionally, devices or structures may bedisposed inside the riser to cause the vapor exiting the riser to swirlor otherwise exhibit characteristics of turbulent flow. FIG. 14 depictshelical slats 356 on the inner wall 357 of riser 140 that cause thevapor in the riser to move in a swirling motion as it exits the riser.Optionally or additionally, the cap 141 may substantially completelyenclose a volume around the riser, as shown in FIG. 15. The bottomsurface 359 of the cap 141 may include flow restrictors such as slots358 or valves 360 to direct or otherwise control vapor exiting the riser(FIG. 16). Additionally and alternatively, the flow restrictors may bedisposed along the lower sides 362 of the cap 141.

FIG. 17 shows a heat exchanger sub-system 310 usable with distillationtower 104, 204. The heating medium is stored in a storage vessel 312.The inlet line is connected to a heater 316, which heats the heatingmedium to a desired temperature. The desired temperature may be a melttemperature of the solid, and/or a melt temperature of one solidselected from a plurality of solids in the middle controlled freeze zonesection 108. In such embodiments, the desired temperature may becontrolled (e.g., by controlling the temperature of the heating medium)such that the selected solid at least partially melts and the at leastone of the plurality of solids does not. The heating medium is thendirected to a pump 318 and finally to the inlet manifold 304. Aspreviously described, the inlet manifold directs the heating medium intothe tubing 302 of the heat exchange mechanism 134, 230, 234, 334 to meltthe accumulated solids and/or selected solid(s) as desired, and theheating medium exits the tubing through the outlet manifold 306. Theheating medium travels back to the storage vessel 312 via a return line320. It is to be understood that the precise arrangement of storagevessel 312, heater 316, pump 318, and heat exchange mechanism 134 may bevaried as desired. Further, design considerations may necessitate notusing one or more elements of the heat exchanger sub-system 310, such asstorage vessel 312.

The heat exchange mechanisms 134, 230, 234, 334 have several advantagesover known tube coil heat exchangers. The coil-in-plate heat exchangemechanisms 134, 230, 234, 334 allow for more tubing to be deployedwithin the same spacing. Additionally, as the tubing is an integral partof the plate from which they are formed, the entire structure of theheat exchange mechanism assumes the temperature profile of the passages,increasing the effective surface area available for heat transfer to theaccumulated solids.

Returning to a description of FIGS. 3-7, the liquid 130 in the melt trayassembly is heated by the vapor stream. The liquid 130 may also beheated by the one or more heat exchange mechanisms 134. The liquid 130helps melt the solids formed in the middle controlled freeze zonesection 108 into a liquid and/or slurry mix. Specifically, the heattransferred by the vapor stream heats up the liquid, thereby enablingthe heat to melt the solids. The liquid 130 is at a level sufficient tomelt the solids.

The middle controlled freeze zone section 108 may also comprise a sprayassembly 129. The spray assembly 129 cools the vapor stream that risesfrom the lower section 40. The spray assembly 129 sprays liquid, whichis cooler than the vapor stream, on the vapor stream to cool the vaporstream. The spray assembly 129 is within the upper section 39. The sprayassembly 129 is not within the lower section 40. The spray assembly 129is above the melt tray assembly 139. In other words, the melt trayassembly 139 is below the spray assembly 129.

The temperature in the middle controlled freeze zone section 108 coolsdown as the vapor stream travels from the bottom of the middlecontrolled freeze zone section 108 to the top of the middle controlledfreeze zone section 108. The methane in the vapor stream rises from themiddle controlled freeze zone section 108 to the upper section 110. Somecontaminants may remain in the methane and also rise. The contaminantsin the vapor stream tend to condense or solidify with the coldertemperatures and fall to the bottom of the middle controlled freeze zonesection 108.

The solids form the liquid and/or slurry mix when in the liquid 130. Theliquid and/or slurry mix flows from the bottom of the middle controlledfreeze zone section 108 to the top of the lower distillation section 106via a line 22 (FIGS. 3-6). The line 22 may be an exterior line thatextends from the middle controlled freeze zone section 108 to the lowersection 106.

The vapor stream that rises in the middle controlled freeze zone section108 and does not form solids or otherwise fall to the bottom of themiddle controlled freeze zone section 108, rises to the upper section110. The upper section 110 operates at a temperature and pressure andcontaminant concentration at which no solid forms. The upper section 110is constructed and arranged to cool the vapor stream to separate themethane from the contaminants. Reflux in the upper section 110 cools thevapor stream. The reflux is introduced into the upper section 110 vialine 18.

After contacting the reflux in the upper section 110, the feed streamforms a vapor stream and a liquid stream. The vapor stream mainlycomprises methane. The liquid stream comprises relatively morecontaminants. The vapor stream rises in the upper section 110 and theliquid falls to a bottom of the upper section 110.

To facilitate separation of the methane from the contaminants when thestream contacts the reflux, the upper section 110 may include one ormore mass transfer devices 176. Each mass transfer device 176 helpsseparate the methane from the contaminants. Each mass transfer device176 may comprise any suitable separation device, such as a tray withperforations, or a section of random or structured packing to facilitatecontact of the vapor and liquid phases.

After rising, the vapor stream may exit the distillation tower 104, 204through line 14. The line 14 may extend from an upper part of the uppersection 110. From line 14, the vapor stream may enter a condenser 122.The condenser 122 cools the vapor stream to form a cooled stream. Thecondenser 122 at least partially condenses the stream. After exiting thecondenser 122, the cooled stream may enter a separator 124. Theseparator 124 separates the vapor stream into liquid and vapor streams.The separator may be any suitable separator that can separate a streaminto liquid and vapor streams, such as a reflux drum.

Once separated, the vapor stream may exit the separator 124 as salesproduct. The sales product may travel through line 16 for subsequentsale to a pipeline and/or condensation to be liquefied natural gas.

Once separated, the liquid stream may return to the upper section 110through line 18 as the reflux. The reflux may travel to the uppersection 110 via any suitable mechanism, such as a reflux pump 150 (FIGS.3 and 5) or gravity (FIGS. 4 and 6).

The liquid stream (i.e., freezing zone liquid stream) that falls to thebottom of the upper section 110 collects at the bottom of the uppersection 110. The liquid may collect on tray 183 (FIGS. 3 and 5) or atthe bottommost portion of the upper section 110 (FIGS. 4 and 6). Thecollected liquid may exit the distillation tower 104, 204 through line20 (FIGS. 3 and 5) or outlet 260 (FIGS. 4 and 6). The line 20 mayemanate from the upper section 110. The line 20 may emanate from abottom end of the upper section 110. The line 20 may extend from anouter surface of the upper section 110.

The line 20 and/or outlet 260 may directly or indirectly (FIGS. 3-6)connect to the line 41. When the line 20 and/or outlet 260 directlyconnect to the line 41, the liquid spray may be pumped to the spraynozzle(s) 120 via any suitable mechanism, such as the spray pump 128 orgravity. When the line 20 and/or outlet 260 indirectly connect to theline 41, the lines 20, 41 and/or outlet 260 and line 41 may directlyconnect to a holding vessel 126 (FIGS. 3 and 5). The holding vessel 126may house at least some of the liquid spray before it is sprayed by thenozzle(s). The liquid spray may be pumped from the holding vessel 126 tothe spray nozzle(s) 120 via any suitable mechanism, such as the spraypump 128 (FIGS. 3-6) or gravity. The holding vessel 126 may be neededwhen there is not a sufficient amount of liquid stream at the bottom ofthe upper section 110 to feed the spray nozzles 120.

FIG. 18 is a flowchart showing a method 500 for separating a feed streamin a distillation tower. At block 502 a controlled freeze zone sectionis maintained in the distillation tower. The controlled freeze zonesection receives a freezing zone liquid stream to form a solid and ahydrocarbon-enriched vapor stream in the controlled feed zone section.At block 504 the solids are selectively melted using a heat exchangemechanism. The heat exchange mechanism includes at least one platepositioned where the solids form within the tower. Hollow tubing formsan integral part of each of the at least one plate. A heating mediumselectively flows through the hollow tubing at a higher temperature thanthe solids to at least partially melt the solids. At block 506 the solidthat has been at least partially melted by the heat exchange mechanismis collected. At block 508 the at least partially melted solid isdisposed of in a manner that separates said at least partially meltedsolid from the hydrocarbon-enriched vapor stream.

FIG. 19 is a flowchart showing a method 600 for producing hydrocarbons.At block 602 a controlled freeze zone section is maintained in thedistillation tower. The controlled freeze zone section receives afreezing zone liquid stream to form a solid and a hydrocarbon-enrichedvapor stream in the controlled feed zone section. At block 604 thesolids are selectively melted using a heat exchange mechanism. The heatexchange mechanism includes at least one plate positioned where thesolids form within the tower. Hollow tubing forms an integral part ofeach of the at least one plate. A heating medium selectively flowsthrough the hollow tubing at a higher temperature than the solids to atleast partially melt the solids. At block 606 the solid that has been atleast partially melted by the heat exchange mechanism is collected. Atblock 608 the at least partially melted solid is disposed of in a mannerthat separates said at least partially melted solid from thehydrocarbon-enriched vapor stream. At block 610 a hydrocarbon-enrichedvapor stream extracted from the distillation tower is produced.

The steps depicted in FIGS. 18 and 19 are provided for illustrativepurposes only and a particular step may not be required to perform theinventive methodology. Moreover, FIGS. 18 and 19 may not illustrate allthe steps that may be performed. The claims, and only the claims, definethe inventive system and methodology.

Disclosed aspects may be used in hydrocarbon management activities. Asused herein, “hydrocarbon management” or “managing hydrocarbons”includes hydrocarbon extraction, hydrocarbon production, hydrocarbonexploration, identifying potential hydrocarbon resources, identifyingwell locations, determining well injection and/or extraction rates,identifying reservoir connectivity, acquiring, disposing of and/orabandoning hydrocarbon resources, reviewing prior hydrocarbon managementdecisions, and any other hydrocarbon-related acts or activities. Theterm “hydrocarbon management” is also used for the injection or storageof hydrocarbons or CO₂, for example the sequestration of CO₂, such asreservoir evaluation, development planning, and reservoir management.The disclosed methodologies and techniques may be used in extractinghydrocarbons from a subsurface region and processing the hydrocarbons.Hydrocarbons and contaminants may be extracted from a reservoir andprocessed. The hydrocarbons and contaminants may be processed, forexample, in the distillation tower previously described. After thehydrocarbons and contaminants are processed, the hydrocarbons may beextracted from the processor, such as the distillation tower, andproduced. The contaminants may be disposed of or discharged as deemedproper. For example, as shown in FIG. 18, the method for producinghydrocarbons may include producing the hydrocarbon-enriched vapor streamextracted from the distillation tower. The method may also includeremoving the hydrocarbon-enriched vapor stream from the distillationtower before producing the hydrocarbon-enriched vapor stream. Theinitial hydrocarbon extraction from the reservoir may be accomplished bydrilling a well using hydrocarbon drilling equipment. The equipment andtechniques used to drill a well and/or extract these hydrocarbons arewell known by those skilled in the relevant art. Other hydrocarbonextraction activities and, more generally, other hydrocarbon managementactivities, may be performed according to known principles.

As utilized herein, the terms “approximately,” “about,” “substantially,”and similar terms are intended to have a broad meaning in harmony withthe common and accepted usage by those of ordinary skill in the art towhich the subject matter of this disclosure pertains. It should beunderstood by those of skill in the art who review this disclosure thatthese terms are intended to allow a description of certain featuresdescribed and claimed without restricting the scope of these features tothe precise numeral ranges provided. Accordingly, these terms should beinterpreted as indicating that insubstantial or inconsequentialmodifications or alterations of the subject matter described and areconsidered to be within the scope of the disclosure. Furthermore, thearticles “the,” “a” and “an” are not necessarily limited to mean onlyone, but rather are inclusive and open ended so as to include,optionally, multiple such elements.

It should be understood that the numerous changes, modifications, andalternatives to the preceding disclosure can be made without departingfrom the scope of the disclosure. The preceding description, therefore,is not meant to limit the scope of the disclosure. Rather, the scope ofthe disclosure is to be determined only by the appended claims and theirequivalents. It is also contemplated that structures and features in thepresent examples can be altered, rearranged, substituted, deleted,duplicated, combined, or added to each other.

What is claimed is:
 1. A method for separating a feed stream in adistillation tower comprising: maintaining a controlled freeze zonesection in the distillation tower, wherein the controlled freeze zonesection is constructed and arranged to form a plurality of solids and ahydrocarbon-enriched vapor stream from the feed stream; maintaining amelt tray assembly within the controlled freeze zone section, whereinthe melt tray assembly is constructed and arranged to at least partiallymelt the solids that are formed in the controlled freeze zone section,and wherein the melt tray assembly comprises a heat exchange mechanismcomprising a plurality of plates having one or more hollow tubingsforming an integral part of the plates, and further wherein the heatexchange mechanism comprises a plurality of passages through at leastone of the plurality of plates, said passages allowing equilibration ofliquid surrounding the at least one plate; at least partially meltingthe solids using the heat exchange mechanism by flowing a heating mediumthrough the one or more hollow tubings that are integrally disposed inthe plates of the heat exchange mechanism, wherein the heating medium isat a higher temperature than the temperature of the solid; collectingthe solid that has been at least partially melted by the heat exchangemechanism; and separating the at least partially melted solid from thehydrocarbon-enriched vapor stream.
 2. The method of claim 1, furthercomprising: selecting the solid from a plurality of solids in thecontrolled freeze zone, wherein at least one of the plurality of solidshas a different melting temperature than the melting temperature of theselected solid; and controlling the higher temperature such that theselected solid at least partially melts and the at least one of theplurality of solids does not.
 3. The method of claim 1, wherein the heatexchange mechanism comprises a plurality of individual, interconnectedheat-exchangers, each of the plurality of individual, interconnectedheat-exchangers including a portion of the plurality of plates.
 4. Themethod of claim 3, wherein the plurality of heat-exchangers are arrangedin a substantially parallel, coiled, or serpentine configuration.
 5. Themethod of claim 1, wherein the melt tray assembly further comprises aplurality of vapor risers, and wherein at least partially melting thesolids further comprises passing vapor through at least one of theplurality of vapor risers.
 6. The method of claim 1, wherein at leastone of the plurality of plates is substantially rectangular in shape. 7.The method of claim 1, wherein at least one of the plurality of platesis conical in shape.
 8. The method of claim 1, wherein at least one ofthe plurality of plates is frusto-conical in shape.
 9. The method ofclaim 1, wherein the plurality of plates are concentrically arranged,with each of the plurality of plates having a different radius ofcurvature.
 10. The method of claim 1, wherein the at least one of theplurality of plates is formed in a spiral.
 11. The method of claim 1,wherein the plurality of plates comprises a plurality of interconnectedsets of plates.
 12. The method of claim 1, wherein at least one of theplurality of plates is disposed to accommodate passage of at least onevapor riser adjacent thereto.
 13. The method of claim 12, wherein the atleast one vapor riser comprises a plurality of vapor risers, at leastone of the plurality of vapor risers having a length different from alength of another of the at least one of the plurality of vapor risers.14. The heat method of claim 12, wherein the at least one vapor riserhas an interior, and further comprising an irregular texture or shape inthe interior of the vapor riser.
 15. The method of claim 1, wherein asurface of at least one of the plurality of plates is textured forenhanced for heat transfer performance.
 16. The method of claim 1,wherein an inner surface of the hollow tubing is textured.
 17. Themethod of claim 1, wherein at least one of the one or more hollowtubings has an orientation of one or more of circumferential, radial,angled, parallel to a diameter of the distillation tower, andperpendicular to the diameter of the distillation tower.